Imagine an electric vehicle without a battery, or better powered by a high-performance storage system, but perfectly integrated into the structure. With flexible design and configurable at pleasure without renouncing a high load capacity. The solution is becoming a reality thanks to researchers at Shanghai University who have developed a strategy for 3D printing lithium-ion structural batteries.
With 3D printing, high-performance and scalable batteries
Instead of being additional external components of an electrical system, the lithium-ion structural batteries developed by the researchers become an integral part of the vehicle. “As far as the design of structural energy storage systems is concerned, the technology focuses mainly on the synthesis and use of materials, as well as on the secondary design of components for the storage of energy,” emphasizes Yinhua Bao, author of the article. It is possible, for example, to improve performance using carbon fiber or to increase sustainability by switching to sodium ions.
In their study, however, Bao’s team focused on creating the most efficient and scalable lithium-ion structural batteries. They then turned to 3D printing, a technology that has made considerable progress in recent years.
“Using 3D printing, we aim to create customizable structures that, when combined with energy storage materials, form components with integrated energy and load storage functions, characterized by high energy density and load capacity,” Bao said.
Disconnected structural batteries to reduce deformation
The researchers’ 3D printing strategy has allowed them to produce a disconnected structure that can effectively reduce the deformations of the accumulator under charge, improving the battery’s mechanical stability.
The first tests showed remarkable results, demonstrating a double resistance to traction and flexion stresses without reducing the energy density. The prototype Bao and his team developed also retained 92% of its capacity after 500 operating cycles.
Thanks to 3D printing, each component of the lithium-ion structural batteries can be produced with the utmost precision, paving the way for various future uses. “The next step in our research will be to explore the application of disconnected structural batteries, such as unmanned aircraft vehicles (UAVs) and robots,” Bao concluded.
The research “Customizable 3D-printed decoupled structural lithium-ion batteries with stable cyclability and mechanical robustness” was published in Composites Science and Technology.